Compac Industries C3000 User manual

COMPAC INDUSTRIES LIMITED C3000 SERVICE MANUAL CONTENTS
23/03/04 Page 1
1. DESCRIPTION .................................................................................................. 4
1.1. General.............................................................................................................................................. 4
1.2. Safety Precautions............................................................................................................................ 5
1.3. Static Electricity Precautions .......................................................................................................... 5
2. MAIN FEATURES ............................................................................................. 6
2.1. Components ...................................................................................................................................... 6
2.2. Configurations.................................................................................................................................. 6
2.2.1. Single Commercial........................................................................................................................ 6
2.2.2. Single Suction Dual Commercial (Duo)........................................................................................ 6
2.2.3. Dual Commercial (Dual or Double) .............................................................................................. 6
2.2.4. Single Retail .................................................................................................................................. 7
2.2.5. Single Suction Dual Retail (Duo).................................................................................................. 7
2.2.6. Dual Retail (Dual or Double) ........................................................................................................ 7
2.2.7. Multi Product (4 hose) Retail ........................................................................................................ 7
2.2.8. Multi Product (4 hose) Retail, Type 'A' all hoses in use................................................................ 7
2.2.9. Multi Product (6 hose) Retail ........................................................................................................ 8
2.2.10. Multi Product (6 hose) Retail, Type 'A' all hoses in use................................................................ 8
2.2.11. Futra (Uses 'Futra' Software)......................................................................................................... 8
3. SET-UP MODES ............................................................................................... 9
3.1. Operating DipSwitch Settings ....................................................................................................... 10
3.1.1. Switch 1....................................................................................................................................... 10
3.1.2. Switch 2....................................................................................................................................... 10
3.1.3. Switch 3....................................................................................................................................... 11
3.1.4. Switch 4....................................................................................................................................... 11
3.1.5. Typical Switch Settings............................................................................................................... 12
3.2. 'K' Factor Switch ........................................................................................................................... 13
3.2.1. Using the ‘K’ Factor Switch........................................................................................................ 13
3.2.2. Calibration ('K') Factor................................................................................................................ 13
3.2.3. No Flow Cut-Off Timer .............................................................................................................. 14
3.2.4. Display (Litres) Resolution ......................................................................................................... 15
3.2.5. Solenoid Delay ............................................................................................................................ 15
3.2.6. Pre-Set Cut-Off ........................................................................................................................... 16
3.2.7. ‘b’ Settings. Air Detection, End of Delivery Flag, and Price Per Litre Display ................................... 16
3.2.8. Configuration Code ..................................................................................................................... 17
3.3. Further Settings Available on the ‘K’ factor Switch................................................................... 19
3.3.1. Product Density Factor................................................................................................................ 19
3.3.2. Specific Density .......................................................................................................................... 19
3.3.3. Temperature Calibration.............................................................................................................. 20
3.3.4. ACV Valve Flowrate................................................................................................................... 20
3.3.5. L-Cut ........................................................................................................................................... 20
3.3.6. H-Cut........................................................................................................................................... 20
3.3.7. F-Cut ........................................................................................................................................... 21
3.4. Parameter Switch........................................................................................................................... 22
3.4.1. Program Version Number ........................................................................................................... 22

COMPAC INDUSTRIES LIMITED C3000 SERVICE MANUAL CONTENTS
23/03/04 Page 2
3.4.2. Setting the Price per Litre ............................................................................................................22
3.4.3. Setting the Product Density .........................................................................................................25
3.4.4. Setting the Dispenser/Pump Number...........................................................................................25
3.4.5. Displaying the End of Sale Indications........................................................................................25
3.4.6. Setting the Sequencing Rate ........................................................................................................25
3.4.7. Validating/Invalidating Cards, Pins, or Keys...............................................................................25
3.4.8. Setting the Access Code ..............................................................................................................26
4. PRINTER SETUP.............................................................................................27
4.1. Comcard, Compin, and CWIDKey Basic Systems. .....................................................................27
4.2. Printer Self Test ..............................................................................................................................27
5. DISPLAYING AND PRINTING TOTALS .........................................................28
5.1. General ............................................................................................................................................28
5.2. Scrolling Tote Option .....................................................................................................................28
5.3. Using a Totals Only - Report Printer............................................................................................28
5.4. Receipt Printer................................................................................................................................28
5.4.1. Printer Housed at the Pump/Dispenser (Card King) ....................................................................29
5.4.2. Receipt Printer Connected to the Central Controller ...................................................................29
6. BASIC SYSTEMS (COMCARD, COMPIN, & CWIDKEY).......................................31
6.1. Comcard Basic ................................................................................................................................31
6.2. Compin Basic ..................................................................................................................................31
6.3. CWIDKey Basic..............................................................................................................................31
6.3.1. CWIDKey Number Identification................................................................................................32
7. ERROR CODES...............................................................................................32
7.1. Other Error Messages ....................................................................................................................32
8. INDICATOR LED’S..........................................................................................34
8.1. General ............................................................................................................................................34
9. SOLID STATE RELAYS (TRIACS) .................................................................35
9.1. General ............................................................................................................................................35
9.2. Changing Solid State Relays..........................................................................................................36
9.2.1. Low Current to Low Current Relay .............................................................................................37
9.2.2. High Current to High Current Relay............................................................................................37

COMPAC INDUSTRIES LIMITED C3000 SERVICE MANUAL CONTENTS
23/03/04 Page 3
10. ELECTRICAL WIRING.................................................................................... 39
10.1. 230 Volt Wiring .............................................................................................................................. 39
10.2. Communications (Comms) Wiring............................................................................................... 40
10.2.1. C3000 Gilbarco Protocol Converter............................................................................................ 41
10.3. Intrinsically Safe Wiring ............................................................................................................... 42
10.3.1. Diesel Air Cut-out Switch ........................................................................................................... 42
10.3.2. Sump Switch (Issue "M" only)....................................................................................................43
10.3.3. Temperature Compensation PCB................................................................................................ 44
10.3.4. Display Backlighting................................................................................................................... 45
10.3.5. Card-readers ................................................................................................................................ 45
10.3.6. Compac Wireless Transceiver.....................................................................................................45
10.3.7. Displays: Litres only, Retail, Multi-price & Preset ..................................................................... 47
10.3.8. Modem ........................................................................................................................................ 47
10.3.9. Standard PIN Pad Unit ................................................................................................................ 47
10.3.10. Secure PIN Pad Unit ................................................................................................................... 48
10.3.11. Encoder ....................................................................................................................................... 48
10.3.12. High/Low Flow Switch ............................................................................................................... 49
10.3.13. High/Low Flow Operation Methods ........................................................................................... 49
10.3.14. Oil Air Bleed Switch ................................................................................................................... 50
10.3.15. Nozzle switch(es) ........................................................................................................................ 50
10.3.16. CNG Dispenser Shut-Off Switch ................................................................................................ 51
10.3.17. Remote Parameter Switch ........................................................................................................... 51
10.3.18. Electromechanical Totalisers ...................................................................................................... 51
10.3.19. Electronic Totals ......................................................................................................................... 51
10.3.20. Distribution Boards ..................................................................................................................... 51
10.4. Mains (220/240Vac) Wiring .......................................................................................................... 52
10.4.1. Pumps/Dispensers without Junction Box .................................................................................... 52
10.4.2. Pumps/Dispensers with Junction Box. (Non LPG or CNG dispensers) ...................................... 52
10.4.3. LPG & CNG Dispensers ............................................................................................................. 52
10.5. Software Upgrade Procedure........................................................................................................ 53
11. FAULT FINDING ............................................................................................. 56
11.1. End of Sale Indications .................................................................................................................. 57
12. GLOSSARY OF TERMS ................................................................................. 59
APPENDIX.............................................................................................................. 60

COMPAC INDUSTRIES LIMITED C3000 SERVICE MANUAL DESCRIPTION
23/03/04 Page 4
1. DESCRIPTION
1.1. General
The Compac 3000 is a microprocessor-based circuit board designed for use in liquid and
gaseous fuel metering. It is suitable for commercial, retail, and bulk-metering applications
and can be used for Tank Gauging, card reader access, and many other control functions.
All descriptions, tables, graphics and drawings in this manual relate specifically to
Issues 'L', 'M' and 'P' of the C3000 PCB.
Figure 1. Layout of C3000 Printed Circuit Board
The C3000 microprocessor, commonly referred to as the 'head', is powered by an
intrinsically safe power supply, and is designed to operate in both a class 1 zone 1 area and
in the vapour-proof box 1.2m above the ground level. If the ‘head’ is used in a class 1 zone 1
area then the power supply and the 230V output circuitry is encapsulated.
The C3000 ('head') performs the following functions (depending upon which accessories are
connected):
•Converts the rotation of a meter into pulses via the Compac Encoder.
•Converts these input pulses into litres.
•Controls the operation of an electric motor or a submersible pump.
•Controls the Preset Valves.
•Provides Temperature Compensation to the litres value.
•Provides Meter correction.
•Provides an electronic 'K-Factor' for calibration. This means that the unit can be used on
any type of meter, regardless of turns per litre.
•Can be fitted with a card-reader directly on the dispenser/pump to give unattended 'fleet'
type access.
•Can be fitted with a PIN / Odometer pad, with or without card reader, on the
dispenser/pump.
•Can be plugged into the Compac Modem Package (Futra only).
Mains
Transformer
MEMORY
SOFTWARE
MODEM
CPU
DIAGNOSTIC
TXD
RXD
WATCHDOG
PARAMETER
SWITCH
‘K’ FACTOR
SWITCH
OPERATING
DIPSWITCHES
POWE
R
CONFIG’
PARA’ S
W
MOTOR
OUTPUT
S
MAINS
TERMINAL
S
SOLENOID
OUTPUTS COMMS
FUSES
AUXILIARY
BACKLIGHTING CARDREADE
R
CHANNEL ‘B’
MAIN DISPLAY
MULTIPRICE DISPLAY
PRESET
CHANNEL ‘A’
MAIN DISPLAY
PRESET
MODEM I/F
PINPAD
KEYBOARD
PINPAD
DISPLAY
ENCODER 3
ENCODER 2
ENCODER 1
NOZZLES
TEST, External Parameter Switch
BUZZER
TOTES
COMMS
DIPSWITCHES

COMPAC INDUSTRIES LIMITED C3000 SERVICE MANUAL DESCRIPTION
23/03/04 Page 5
•Has a real time clock for memory and card-reader reporting functions (Futra only).
•The Display options available are (no. of digits in parenthesis):
°Litres only
°Dollars, litres and price (5 x 5 x 4) & (6 x 6 x 4)
°Litres, Rate of Flow and Preset
°Multi-price display
°Preset
°Last Sale, kilograms, dollars and price (CNG only)
•Can report by any of the following options:
°Card/Pin/Key Totals printout (Comcard, Compin, & CWIDKey only)
°Card/Pin/Key Transaction Audit Trail printout - Small Docket Printer (Comcard,
Compin, & CWIDKey only)
°Receipt Printout - Small Docket Printer (Central Controller & Futra systems)
°Audit Trail/Report Printout of transactions - 11" Report Printer (Central Controller &
Futra only)
1.2. Safety Precautions
The C3000 head, and its associated circuits and wiring, is certified electrical equipment
approved for use in a hazardous area (Class 1 Zone 1, Group IIA T3). Only parts identical to
those covered by the certification may be used where the integrity of the intrinsic safety may
be affected. All circuit boards are only to be repaired by Compac Industries Ltd.
1.3. Static Electricity Precautions
Electronic components used are sensitive to static. Please take anti-static precautions.
All circuit boards must be carried and transported in static-shielded bags. An anti-static wrist
strap should be worn and connected correctly when working on any electronic equipment. If
an anti-static wrist strap is unavailable, or in an emergency, hold onto an earthed part of the
pump/dispenser frame whilst working on the equipment. This is not a recommended
alternative to wearing an anti-static wrist strap.
Note: Compac Industries Limited reserves the right to refuse to accept any circuit boards returned, if proper
anti-static precautions have not been taken.

COMPAC INDUSTRIES LIMITED C3000 SERVICE MANUAL MAIN FEATURES
23/03/04 Page 6
2. MAIN FEATURES
2.1. Components
The main components associated with the C3000 head are:
•Remote Distribution Board
•Encoder
•Displays
°Litres
°Dollars, litres and price
°Litres, rate of flow and preset
°Multi-price display
°Preset
°Last Sale, kilograms, litres and price
(CNG only)
•Temperature compensation
•Card-reader
•PIN/Odometer Pad
•Printer
•Modem
•
Tank Gauging Probe (only available with
Futra Option)
•Mechanical Totaliser (Tote)
•Nozzle Switch
2.2. Configurations
The C3000 'head' can be used with the equipment listed below in the following standard
configurations:
2.2.1. Single Commercial
Standard Options: Extras:
•Litres only display, two - one per side
•Motor circuit, one only
•One Encoder
•One Nozzle Switch
•C3000 Head
•Card-reader
•High/Low Flow Operation
•Temperature Compensation
•PIN-Pad
* Also see 'FUTRA' configuration.
2.2.2. Single Suction Dual Commercial (Duo)
Standard Options: Extras:
•Litres only display, four - two per side
•Two motor circuits
•Two Encoders
•Two Nozzle Switches
•C3000 Head
•Temperature Compensation
•Preset
2.2.3. Dual Commercial (Dual or Double)
Standard Options: Extras:
•Litres only display, four - two per side
•Two Motor circuits
•Two Encoders
•Two Nozzle Switches
•C3000 Head
•Temperature Compensation
•Preset

COMPAC INDUSTRIES LIMITED C3000 SERVICE MANUAL MAIN FEATURES
23/03/04 Page 7
2.2.4. Single Retail
Standard Options: Extras:
•Dollars, litres and price display, two - one per
side
•Presets, two - one per side
•One Encoder
•One Nozzle Switch
•One Motor Output
•C3000 Head
•Card-reader
•Temperature Compensation
•PIN-Pad
•Receipt Printer
* Also see 'FUTRA' configuration
2.2.5. Single Suction Dual Retail (Duo)
Standard Options: Extras:
•Dollars, litres and price display, two - one per
side
•Presets, two - one per side
•Two Encoders
•Two Nozzle Switches
•Two Motor Outputs
•C3000 Head
•Temperature Compensation
2.2.6. Dual Retail (Dual or Double)
Standard Options: Extras:
•Dollars, litres and price display, four - two
per side
•Presets, four - two per side
•Two Encoders
•Two Nozzle Switches
•Two Motor Outputs
•C3000 Head
•Temperature Compensation
2.2.7. Multi Product (4 hose) Retail
Standard Options: Extras:
•Dollars, litres and price display, two - one
per side
•Presets, two - one per side
•Four Encoders
•Four Nozzle Switches
•Four Motor Outputs - two per C3000 Head
•Two C3000 Heads (for Issue "L")
•One C3000 Head (for Issue "M") and
Version 25 software
•Multi-price Displays, four – one per product
per side
•Card-reader
•PIN Pad
•Receipt Printer
2.2.8. Multi Product (4 hose) Retail, Type 'A' all hoses in use
Standard Options: Extras:
•Dollars, litres and price display, four - one
per product per side
•Presets, four - one per product per side
•Four Encoders
•Four Nozzle Switches
•Four Motor Outputs - two per C3000 Head
•Two C3000 Heads (Issue "L")
•One C3000 Head (Issue "M") and Version 25
software
•Temperature Compensation

COMPAC INDUSTRIES LIMITED C3000 SERVICE MANUAL MAIN FEATURES
23/03/04 Page 8
2.2.9. Multi Product (6 hose) Retail
Standard Options: Extras:
•Dollars, litres and price display, two - one
per side
•Presets, two - one per side
•Six Encoders
•Six Nozzle Switches
•Six Motor Outputs - three per C3000 Head
•Two C3000 Heads
•Multi-price Displays, six - one per product
per side
•Card-reader
•PIN Pad
•Receipt Printer
2.2.10. Multi Product (6 hose) Retail, Type 'A' all hoses in use
Standard Options: Extras:
•Dollars, litres and price display, six - three
per side
•Presets, six - three per side
•Six Encoders
•Six Nozzle Switches
•Six Motor Outputs - two per C3000 Head
•Three C3000 Heads (Issue "L")
•Two C3000 Heads (Issue "M") and Version
25 software
•Temperature Compensation
2.2.11. Futra (Uses 'Futra' Software)
This type of system is a stand-alone system that cannot be set up to communicate to any type
of controller.
Standard Options: Extras:
•Litres Only Display
•Motor Circuit (One only)
•One Encoder
•One Nozzle Switch
•C3000 Head
•PIN-Pad
•CardReader
•Retail Displays
•Preset
•Modem
•Temperature Compensation
•High/Low Flow Operation
•Tank Gauging, for one tank only
•Receipt Printer

COMPAC INDUSTRIES LIMITED C3000 SERVICE MANUAL SET-UP MODES
23/03/04 Page 9
3. SET-UP MODES
To enable the C3000 to operate as desired, 3 things must be set:
1. Operating Dip Switches
•A Block of 4 sliding switches.
2. Configuration (K Factor) Switch Settings
•This switch accesses different options that must be set appropriately for the particular
type of dispenser.
3. Parameter Switch Settings
•This switch is used to conduct the Display Segment Test, set price (product density - if a
bulkmeter), and set pump number. Also, when the C3000 is configured for 'Comcard',
'Compin', or 'CWIDKey' the parameter switch is used for card/pin/key validation and for
setting the card/key system number (access code - refer section 3.4.8).
•With CNG dispensers, the sequencing rate between 'banks' is also set using the parameter
switch (reference section 3.4.6).
The positions of the above switches are shown on Figure 1, page 4. Also, note that a second,
more readily accessible parameter switch is mounted in all pumps/dispensers. This gives
quick access for service station staff to make changing price easier. Set up of the C3000
must be done in the following sequence:
1. Operating Dipswitch Settings (power OFF the C3000 before changing)
•To be set, before 'powering up'.
2. ‘K’ Factor Switch Settings - starting with configuration setting and moving back through
the options to the K Factor setting:
‘K’ Factor Switch Settings
Setting Price Display Litres Display Reference
Configuration Code ‘C’ ‘XXXXX’ Refer section 3.2.8.
Display Resolution ‘Sr’ ‘X.XX’ Refer section 3.2.4.
Temperature ‘E’ ‘E XXX.X’ Refer section 3.3.3. LPG and
Bulk-metering only
ACV Flowrate ‘FLO’ ‘r XXXX’ Refer section 3.3.4. Bulk-
metering only
Specific Density ‘dEn’ ‘XXX.X’ Refer section 3.3.2. LPG only.
No-flow cut-off ‘n’ ‘n XXX’ Refer section 3.2.3
Solenoid delay ‘Sd’ ‘d XXX’ Refer section 3.2.5
Preset Cut-Off ‘PCut’ ‘PC X.XX’ Refer section 3.2.6
‘b’ settings ‘b’ ‘b XXXX’ Refer section 3.2.7
‘K’ Factor ‘F’, ‘Fb’, ‘F1’,
‘F2’, or ‘F3’
‘X.XXXX’ Refer section 3.2.2
H-Cut ‘HCut’ ‘HXXXX’ Refer section 3.3.6. Bulk-
metering only
L-Cut ‘LCut’ ‘LXXXX’ Refer section 3.3.5. Bulk-
metering only
F-Cut ‘FCut’ ‘FXXXX’ Refer section 3.3.5. Bulk-
metering only
Density Factor ‘dSF’ ‘X.XXXX’ Refer section 3.3.1. CNG only

COMPAC INDUSTRIES LIMITED C3000 SERVICE MANUAL SET-UP MODES
23/03/04 Page 10
SP: Set decimal place. Appears only when the unit is set-up for CNG.
NOTE: The K Factor setting should be done last of all (i.e. until parameter switch settings are
made, the pump/dispenser may not be operational, and so a calibration fill may not be possible).
3. Parameter Switch Settings - all must be set, but order of set-up is not critical.
3.1. Operating DipSwitch Settings
The location of the block of four DipSwitches on the Processor Board is shown in Figure 1
on page 4.
Dipswitch ON/OFF Brief description of dipswitch function
1OFF Display Error checking on.
ON New style displays (Use 8x1 pinheader connections)
2OFF Normal operation
ON Comcard or CWIDKey Basic systems
3OFF Normal operation. (Pump start is controlled by the nozzle switch)
ON Auto-authorise mode. (Pump starts on being authorised)
4OFF Will operate “stand alone”. (does not require a controller)
ON Requires the presence of a controller to start the pump.
3.1.1. Switch 1
If Switch 1 is OFF, the display will automatically check the data.
•Dollars
•Litres
•Price
NOTE: In order to use an old style display, wiring modifications must be done if it is to be used
on Issue "L" and/or Issue "M".
If Switch 1 is ON, the latest type Commercial, Retail, or Multi-Purpose displays are being
used.
•Litres
•Dollars, Litres, Price
•Litres, Rate of Flow, Preset
NOTE: The old type of display pin is a 6 x 2 (Issues A thru E) and the new type of display pin is
an 8 x 1.
3.1.2. Switch 2
If Switch 2 is ON, the head is set up for Comcard Basic, or CWIDKey Basic, which are self-
contained systems operating independently of any controller.
•To operate, a card-reader/CWIDKey reader must be plugged into the 'head' and the
correct access code and card/key number validations must be set by the Parameter switch.
If Switch 2 is OFF, the system will function as a conventional dispenser/pump.
•For the Bulk Meter Register, Switch 2 must be off. Comcard, and CWIDKey Basic
systems are not available in this mode.